Tufting machine yarn feeding means



Seph- 17,' E. 'B.BROADRICK ETAL 3,103,903 I T UFTING MACHINE'YARN'FEEDING' MEANS SePf- 17, 1963 E. B. BRoADRlcK ETAL 3,103,903

TUF'TINGv MACHINE YARN FEEDING MEANS 3 Sheets- Sheet 2 Filed Jan. 25,1960 1963 E. B. BRoADRlcK ETAL Y 3,103,903

TUFTING MACHINE YARN FEEDING MEANS Sept. 17,

United States Patent G 3,103,963 TUFTING h/IACHEHNE YARN FEEDENG MEANSEd B. Broadrielr, Tiger, Glenn l. Ledtord, Clayton, and Herbert S.McDowell, Mountain City, Ga., assigner-s to .lames Lees and SonsCompany, Bridgeport, Pa., a corporation of Pennsylvania Filed San. 25,1960, Ser. No. 4,445 11 Claims. (Cl. 1112-79) This invention pertains topattern attachments for pile fabric tufting machines and moreparticularly to a universal roller-type pattern attachment havingdisconnectable roller segments permitting use of the same attachmentIfor various fabric widths.

In the carpet industry the customary widths for broad fabrics are 9',12', 15', and 18'. Where it is desired to produce a fabric having aSculptured pile surface, a wellknown form of pattern attachment is usedwhich produces this surface due tto controlled feed and/or tens-ion inthe pile yarns. Such an attachment usually comprises a series of rollersmounted in banks in front of and over the tufting machine proper. Groupsof yarns are fed over pairs of rollers, eac-h pair of which has two ormore speeds controlled by electrically operated clutches. A patternchain or cylinder operates suitable electrical connections forenergizing the electrical means to vary the relative feed of the yarnsthreaded around each pair of rollers. if a particular broad machine, saywide, is fully lthreaded and it should be desired to produce a narrowerAfabric on this machine only 9' or 12' wide, it is necessary to doit allof the unused pile yarn ends from the pattern attachment. This requiresunthreading them from around ;12 or 14 rollers.

'Ilhe present invention contemplates the use of segmented rollers forthe pattern attachment which may be disconnected either manually orelectrically from the center section of each roller, thus permitting theunused yarn ends to remain on the stationary segments and thereby avoidthe necessity for the unthreading and rethreading operation. In thepreferred embodiment of the invention an outer disconnectable segment isplaced on each of the roller shafts. This permits a reduction in widthfrom approximately l5' to l2'. A second disconnectable roller segmentcan then be, if desired, disconnected `from the center section at eachend so that the effective width is only 9'. Of course, the outer two orthree segments on each roller can, if desired, be disconnected as aunit, thus directly changing from 18' or l5' to 9' Widths.

The invention also contemplates the use of suitable means forrotationally locking the disconnected segments so that even though theroller shafts are turning in the segments there will be no possibilitythat the unused segments will rotate with the consequent effect oftang'ling yarn ends on these segments.

A primary object of the invention, therefore, is to provide in a rollerpattern attachment for a pile fabric tufting machine at least onedisconnectable segment for the yarn feed pattern rollers.

A further object of the invention is to provide in a roller patternattachment for a pile ,fabric tufting machine a plurality of axiallymovable segments on each end of each pattern roller and means forlocking the segments together in driving relationship with the rollershaft.

A further object fof the invention is to provide in apparatus of thetype described, spring loaded detent means for retaining thedisconnectable segments in an interlooked position.

A still further object of the invention is to provide electromagneticmeans for retaining the segments in interlocked and driving position.

3,163,963 Patented Sept. i7, 1963 lee A still further object is toprovide in apparatus of the type described means for retainingdisconnected roller segments in a fixed position.

Further objects will be apparent from the specification and drawings inwhich:

FIG. 1 is la schematic sectional view of a broad pile fabric tuftingmachine having a seven roller pattern attachment,

FIG. 2 is a schematic view of the pattern attachment of FIG. 1 showingthe locking means for preventing rotation of disconnected rollersegments,

FIG. 3 is a Itop view of a pair of pattern rollers as seen at 3-3 ofFIG. 1,

FIG. 4 is an enlarged sectional detail as seen at 4 4 of FIG. 3,

FIG. 5 is an enlarged sectional detail as seen at 5--5 of FIG. 3,

FIG. 6 is an enlarged sectional detail as seen ait 6--6 of FIG. 3,

FIG. 7 is a section as seen at 7--7 of HG. 5,

FIG. 8 is a perspective of the connection of FIG. 6,

FIG. 9 is an enlarged sectional ldetail similar to FIG. 5 but showingelectrical locking means for the disconnectable segments,

FIG. 10 is a section as seen at lll-ltl of FIG. 9,

FIG. 1"1 is a section as seen at 11-11 of FIG. 9,

FIG. ,12 is a section as seen at 12-12 of FIG. 9,

FIG. #'13 is a View similar to FIG. 9v showing a modified form oflocking device :for the roller segments,

FIG. 14 is a section as seen at 14--14 `of FIG. 1'3,

FIG. l5 is a section as seen at 1'5-15 of FIG. 13,

FIG. 16 is a schematic showing of a varied form of disconnected segmentclamping device, and

FIG. 17 is a sectional view as seen at 117-17 of FIG. 16.

A pile fabric tufting machine of the type on which the present inventionis utilized comprises a bed Ztl over which a backing fabric F is 'fedfrom a pin feed roll 21 over roller ZZ `and around a pin take-up roll23'. A series of tufting needles 24 are secured in a needle bar 25supported on rods 26, Z6 and vertically oscillated from the crankshaft27 through connecting rods 28 A presser foot assembly 29 is connected tothe needlebar as is the usual thread jerker 30. The above crankshart andits associated structure is enclosed and -is journaled in an upperhousing 31.

'Ilhe needles 24 reciprocate to carry the pile yarn Y through thebacking `fabric F at the throat 35 of the tufting machine where a seriesof loopers 36 engage the yarns Y at each needle and thereby form thepile on the underside of fabric F. The present showing indicates aseries of non-cutting loopers which are mounted in a looper bar A37clamped to looper rockshaft 38 which oscillates to move the loopers intoand out of the pile yarns Y.

The pile yarns Y are fed from -a convenient source such as a ereel, notshown, and are separated into groups it? and 4l. Each group is thenthreaded around a pair of pattern rollers ft2 and 43. Depending upon thenurn- 'ber of groups and the number of yarn ends, the pairs of 'rollersvary from a single pair to as many as seven pai-rs, such as shown inFIG. 1. Although there are actually 14 rollers in the patternattachment, such an attachment is customarily referred to as a sevenroller attachment indicating the number of pairs rather than the nurnberof individual rollers. Each of the yarn sets 40 and 41 is carriedthrough a yarn guide bar 44 in front of its associa-ted roller pair andthe yarn sets pass under each feed roller 42 and over the rear roller43. From thence the yarns pass through `a rear guide bar 45, stationaryyarn guides i6 and 47, and then through the yarn jerker 30. Since eachpair of rollers in the pattern attachment 3 shown in FiGS. l and 2 isidentical to each other pair and they operate in the same manner, theadditional rollers have been designated with suitable subscripts whichalso apply to the associated yarn guides.

Referring now more particularly to FIGS. 3-8, each of the rollers f1.24and 43 is, in fact, a :segmented roller having disconnectable sets ofsegments at each end. Since the construction of each roller isidentical, it will he suicient to describe the `front roller 42 of thetop pair Ibut each roller in the lower pairs is similar. Front roller 42is driven through its shaft 50 by the usual driving means, not shown.However, a driving interconnection between the rollers of each pair isprovided through a pair of spur gears 51 `and 52 mounted respectively onshaft of roller `42 and shaft 53 of roller 43. `Both rollers arepreferably provided with two intermediate supporting bearings shown at54, 54 in FIG. 3. Describing now particularly roller 42, the centersegment 55 of roller 42 is permanently pinned or keyed to shaft 50.

This segment 55 in a broad tufting machine is approximately 9 in lengthor at least suiciently more than 9 to accommodate all of the pile yarnsY needed to produce a `full 9 width. Each end of roller 42 is providedwith three individually disconnectable segments. The lirst segments,approximately 11/2 in length, are designated 6G and 60a, the second pairalso approximately ll/z' in length, 61 and 61a, and the third pair whichare desirably somewhat longer than 1%. are designated 62 and 62a. Thecorresponding segments on roller i3 are designated with primed numeral-sin FIG. 3, but it will be understood as stated above that each of therollers is identical.

Referring now to FIGS. 5 8, the disconnectable drive for the varioussegments comprises a cut-away portion which may be described as a halfsector 65 secured in its corresponding segment, for example, segment 62,by means of screws or rivets 66, 66. The mating segment, for example, 61(FIG. 8) comprises a collar 67 secured to segment 61 by means of screwsor rivets 68, 68 and having a half ysector 69 similar to half sector 65.Opposite faces of half sectors 65 and 69 are provided with spring loadeddetents 7) and 71 biased in the `sector by means of compression springs72 and 73. The mating face of sector 65 is provided with small dimplesor depressions 74 and 75 into which the detents 7i) and 71 snap when thesegments 61 and 62 are interlocked by means of axial movement on shaft50. Either or both of the collars 67 and 76 may be provided withantifriction bushings 77 and 7S if desired. Similar bushings are `usedwith the plain collar 79 at the outboard ends of segments 62, 62', 62a,and 62a. The identical interlocking connection is employed betweensegments 61, 62; 60, 61; 60a, 61a; 61a, 62a; 62'a, 61a; 61a, ila; 61';61', 62 on each pair of rollers 4t2 and 43.

Segments 55, 66, 60a, 6tla, and 69 are permanently secured to theirrespective shafts 50 and 53 as shown in FIG. 4. A plain collar 30 ispinned -through the sleeve of `segment 6i) and shaft 50 by means of ataper pin 81. Similar 'bushings S2, 83, and S4 are used for segments 55and 60a and are in turn anchored to shaft Si) by means of taper pins 35,86, and S7.

In order to prevent rotation of all disconnected segments having yarnends trained around such disconnected segments, we provide a movableframework assembly 95 (FIG. 2) which is slidable underneath each of theroller shafts to engage the tlats of half sectors 69, etc., therebypreventing .undesired rotation of the disconnected segments. Eachassembly is provided with a series of substantially horizontal bars orpins 96, 96 which contact the underside of shafts 50, 53 when moved intoan operative or forward position as shown in FIG. 6. Three sets of pins96 are shown in a retracted position in FIG. 3 whereas the fourth sethas been displaced to engage segments 62 and 62 to prevent rotationthereof. Ordinarily the outer segments are not only disengaged on eachroller of a pair but also at each end of each roller to provide anapproximate reduction in the total width of the fabric of three feet.However, for purposes of illustration, FIGURE 3 at the left end showsrollers 42 and 43 completely interlocked as would be the case for fullwidth operation, but at the right end the outermost segments 62 and 62'have 'been disconnected and nonrotatably anchored by means of pins 96the corresponding pins for each pair of rollers are identied with aletter exponent corresponding with the pairs of rollers with which theycooperate as seen in FIGURES l and 2. Each framework assembly issupported on rails 97 slidable in sleeves 98 `and provided with stoppins 99 (FIG. 1). Also, it will .be understood that the correspondingsegments on each of `the pattern rollers 42 and #53 would normally bedisconnected `from top to bottom since the seven groups of yarns wouldin most patterns extend laterally the full width of the fabric. Thepattern rollers illustrated herein have two disconnectable segments ateach end thus providing a choice of three widths, namely, 9', l2', andl5'. For 18 tufting machines it is only necessary to add another segmentto each end of each roller. In any particular design it might bedesirable to disconnect less than all of the corresponding segments ofeach roller in which event a somewhat modified means for retaining theindividual segments would be utilized. An example of such modifiedlocking means would be described more fully in conjunction with FIGS. 16and 17.

Referring now to FiGS. 9-l5, a modified form of disconnectable drivingelement for the various segments will be described. Here again it willbe understood that the connection for only two segments is illustratedbut that the identical device will be employed for each of the variousseparable segments. In FIGURE 9 a pattern roller segment 1d@ is showndrivingly connected with an adjacent segment 13-1, the latter of whichis non-rotatably pinned to shaft 162 through collar 163 and taper piny16M. In the form of FIGURE 9, segment 191 is provided with an armature195 of some magnetically permeable material locked in segment 161 bymeans of electrical insulating material 166. An electrical coil 167 ispositioned in segment y15.11B* and likewise is provided with suitableinsulating bushings tit and `169. When coil 167 is energized in a mannerto be described later, the armature 1125 and electromagnet tightly gripeach other to provide a driving connection between the segments 19t) and161.

rhe electrical connections for energizing and de-energizing coil 107 arecarried through the hollow bore 115 of shaft 102 in the form of a pairof electrical leads 116 and `117 terminating at binding posts 113 and119 mounted on a collar 129 which is fixed to shaft 102. The bindingposts are electrically connected to two collector rings 121 and 122mounted in the face of collar 120. A pair of spring loaded brushes 123,124 are urged against the respective collector rings 121 and 122 bymeans of brush springs 125 and 126. Current flows from brush 123 to`coil 167 through pigtail 127. Similarly, current from collector ring122 is carried through brush 124, pigtail 12S, to coil 167. The coil ismaintained in position by means of the dielectric bushing '163 securedby four screws 130, `130. When coil 1637 is dta-energized, relativerotation of segment 166 on shaft 1112 takes place without perceptibleaxial movement of the segment on the shaft. The opposite end of segment169 is journaled for this purpose on a collar mounted on ananti-friction bushing 136. Collar 129, however, turns with shaft 162 toprevent fouling of the electrical leads 116 and 117. As soon as the coil107 is energized by the operator, segment l1G11 is driving/ly connectedwith segment 101, thus permitting it to rotate as a unit with shaft 192in the usual manner.

A further modified form is shown in FIG. 13 in which the segment 160 isdrivingly connected to segment 101 by means of one or more magneticallydisplaceable keys or pins which are moved axially in collar 141 by meansof coils 1li?. and 165. When in loci-:ing position, as shown at the topof FIG. 13, the pins 14d drivingly connect the collar 141 'with collarv146 pinned to shaft 102 at 147. When pins 140 are retracted due toenergization of coils 142 and 145, they are retained by means of threespring detents 150 which are provided with bent up ears 151 as seen inFIG. 13 and anchored to posts 152 by means of screws 153 (-FIG. 14). Thedetents 150 operate against a spider 154 which mounts and guides thethree pins 140. Displacement of the detents by the beveled periphery ofthe spider serves to lock the three pins in either a driving ordisconnected position so that it is only necessary to momentarilyenergize one of the coils 142 and 145 in order to lo-ck or disconnectthe segments 100 and 101. Coil 142 when energized disconnects thesegments since it pulls the pins to the right as seen in FIG. 13. Tolock the segments the operator merely presses another switch -whichenergizes momentarily coil 145, thus `shifting the pin assembly. It istherefore unnecessary to have either of the coils energized for asubstantial length of time in order to retain the segments in either adriving or a disconnected position. With the electromagnet of FXGURE 9such indefinite energization of coil 107 must take place regardless ofwhether the segments are connected or disconnected.

In order to retain the disconnected segments in a relatively stationaryposition regardless of Whether they are of the mechanical or electricalvariety, we provide a bracket 175 (FIG. 17) which extends betweenadjacent pairs of rollers 42 and 43. The bottom of the bracket 45 has aspring loaded clamp 176 which can be urged into contact with theperiphery of rollers 42 and 43 by means of a cam 177 controlled by lever178. Shaft y179 for the lever is desirably mounted in a pair of bearings180, 180cm any convenient structural framework member, not shown.Pivoting of lever 17S compresses spring 181 and urges plate 176 againstthe periphery of rollers 42 and 43 so that they remain stationary whentheir respective shafts rotate.

It will be understood that the locking means shown in FIGURES 1 and 17are illustrative of several forms that can be desirably employed toretain disconnected segments in a relatively stationary condition shouldsuch procedure be necessary or desirable to prevent fouling of theunused yarns trained over the disconnected segments. Where the frictionis extremely slight bet-Ween the disconnected segments and theirrespective shafts, the drag of the yarn itself may be suicient.

We have thus described an eflicient improvement in pattern attachmentsfor broad tufting machines commonly known as yardage machines in theindustry which permits much greater flexibility in the manufacturingoperation. lt is no longer necessary for the manufacturer to havedifferent width machines unless he can keep every machine operating atfull capacity. With a far lesser number of machines the manufacturer isnow able to quickly convert to one or more different widths, thusaffecting a s-ubstantial saving in door space required and capitalinvestment.

Having thus described our invention, we claim:

1. A pattern attachment for use with a pile fabric tufting machinehaving a plurality of needles for inserting pile yarns through a backingfabric, comprising a series of yarn feeder main rollers over pairs ofwhich a 'group of pile yarns is trained, at least one end segment rolleron at least one end of each of said main rollers in axial alignmenttherewith, a shaft for each of said main rollers and its correspondingsegment roller with each of said main rollers fixed to its shaft forrotation therewith, interconnecting drive means between the shafts ofeach pair of main rollers for positively driving same, and means forselectively and drivingly engaging each of said end segment rollers withits associated main roller.

2. Apparatus in accordance with claim l, in which each end segmentroller is axially slidable on its shaft into and out of rotationalengagement with its corresponding main roller, each main roller andsegment roller respectively having complementary half-sectors positionedtherein for `detachable interlocking engagement With one another.

3. Apparatus in accordance with claim 2, wherein the half-sector of eachsegment roller is provided with a spring loaded detent and eachcomplementary half-sector of each main roller is provided with adepression complementary with said detent for retaining thecomplementary half-sectors in detachable relationship.

4. Apparatus in accordance with claim 1, including means for retainingthe end segment roller, when in disconnected engagement from itscorresponding main roller, in non-rotational relationship with itscorresponding shaft.

5. Apparatus in accordance with claim 4, wherein the retaining meanscomprises a framework having a series of horizontally extending pins,said pins being movable into and out of engagement with said segmentroller, when in a disconnected state, to prevent rotation of same withits associated shaft.

16. Apparatus in accordance with claim 1 in which the engaging meanscomprises an electromagnet, a coil for selectively energizing andtie-energizing said electromagnet, and a magnetically permeable armaturepositioned to be locked to the magnet when the coil is energized.

7. Apparatus in accordance with claim l in which the engaging meanscomprises a plurality of pins axially movable with respect to the endsegment, an electric coil for moving said pins from a drivingly engagedto a drivingly ydisengaged position, and spring loaded means forretaining the pins in either of said positions.

8. A pattern attachment for use with a pile fabric tufting machinehaving a plurality of needles for inserting pile yarns through a backingfabric, comprising a series of yarn feeder central rollers over pairs ofwhich a group of pile yarns is trained, at least one end segment rolleron each end of said central roller in axial alignment therewith, a shaftfor each of said central rollers and its corresponding end segmentrollers, with each of said main rollers fixed to its shaft for rotationtherewith, in-

terconnecting drive means between the shafts of each` pair of lfeedrollers for positively driving same, detachable locking means betweeneach end segment roller and its associated central roller for connectingone to the other in releasable engagement therewith, and means forretaining the end segment rollers, when in a disconnected state, innon-rotatable relationship.

9. yIn pile fabric tufting apparatus having a throat plate, means forfeeding backing fabric across said throat plate, a plurality ofoscillating needles Ifor penetrating the fabric as it is fed over thethroat plate, and a plurality of pairs of rollers for feeding pile yarnto said needles, the improvement of at least one disconnectable segmentroller forming the terminal portion of at least one end of each of saidfeed rollers and being in axialV alignment therewith, and means forselectively retaining said disconnectable segment rollers in anon-rotatable position when said disconnectable segment rollers are in adisconnected position with respect to said feed rollers.

10. yIn pile fabric tufting apparatus having a throat plate, means yforfeeding backing fabric across said throat plate, a plurality ofoscillating needles for penetrating the fabric as it is fed over thethroat plate, anda plurality of pairs of rollers :for feeding pile yarnto said needles, the improvement of at least one disconnectable segmentroller forming the terminal portion of atleast one end of each of saidfeed rollers and being in axial alignment therewith, an electromagnetpositioned in each of sai-d segment rollers adjacent one end thereof,means for energizing and de-energizing said magnet, an armature in theend of each feed roller associated with its corresponding segmentroller, and electrical connections from the coil through the segmentrollers.

1l. In pile fabric tufting apparatus having a throat plate, means forfeeding backing fabric across said throat plate, a plurality ofoscillating needles for penetrating the fabric as it is fed over thethroat plate, and a plurality of pairs of rollers for feeding pile yarnto said needles, the improvement of at least one disconnectable segmentroller forming the terminal portion of at least one end of each of saidfeed rollers and being in axial alignment therewith, at least oneslidable key member between each of said feed rollers and its associateddisconnectable segment roller, a coil for axially sliding said keymember into engagement to drivingly disconnect the roller and itsassociated disconnectable segment roller, a second coil for axiallysliding the key member to dis connect the segment roller from itsassociated roller, and

55 retaining means for the lkey member to hold it in either engaged ordisengaged position.

References Cited in the le of this patent UNITED STATES PATENTS1,125,761 Strong Jan. 19, 1915 2,213,552 Scharr Sept. 3, 1940 2,412,013Shade Dec. 3, 1946 2,712,682 Warner July 12, 1955 2,811,244 MacCarayOct. 29, 1957 2,876,441 Boyles Mar. 3, 1959 2,932,181 MacCaffray Apr.12, 1960

9. IN PILE FABRIC TUFTING APPARATUS HAVING A THROAT PLATE, MEANS FORFEEDING BACKING FABRIC ACROSS SAID THROAT PLATE, A PLURALITY OFOSCILLATING NEEDLES FOR PENETRATING THE FABRIC AS IT IS FED OVER THETHROAT PLATE, AND A PLURALITY OF PAIRS OF ROLLERS FOR FEEDING PILE YARNTO SAID NEEDLES, THE IMPROVEMENT OF AT LEAST ONE DISCONNECTABLE SEGMENTROLLER FORMING THE TERMINAL PORTION OF AT LEAST ONE END OF EACH OF SAIDFEED ROLLERS AND BEING IN AXIAL ALIGNMENT THEREWITH, AND MEANS FORSELECTIVELY RETAINING SAID DISCONNECTABLE SEGMENT ROLLERS IN ANON-ROTATABLE POSITION WHEN SAID DISCONNECTABLE SEGMENT ROLLERS ARE IN ADISCONNECTED POSITION WITH RESPECT TO SAID FEED ROLLERS.